CLSS

1
• Hydraulic Systems
The industrial hydraulics system is a power transmission

system using a fluid to carry the power. Transmission of
power with a contained liquid as an essential link in a
transmission system can be accomplished by two separate
and distinct systems.
Hydrodynamic Systems
Hydrodynamic systems depend upon the inertia of the

moving fluid to accomplish the desired power transmission
function. These systems are called hydrodynamic because
of the energy transfer pattern. The hydraulic coupling in
an automotive-type automatic transmission provides a
good example of a hydrodynamic power transmission
system.
Hydrostatic Systems
Liquid contained within an enclosed conductor is moved

and pressurized by a positive-displacement pumping
mechanism in a hydrostatic-type system. The energy
implanted by the pump mechanism on the liquid is then
available to move a linear hydraulic cylinder for push or
pull action or to a rotary hydraulic motor for rotary force
and motion. Pumps can be structured accomplish the
desired liquid movement with several different basic
design characteristics.
Department of Mechanical Engineering

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• Major Hydraulic Components
• Types of Hydraulic Circuits

There are generally two types of hydraulic systems:
1. Open-Centre System
2. Closed-Centre System
Open-Centre System
In this system, a control-valve spool must be open in the

center to allow pump flow to pass through the valve and
return to the reservoir. To operate several functions
simultaneously, an open-centre system must have the
correct connections; an open-centre system is efficient on
single functions but is limited with multiple functions.
This type of system is commonly used with fixed

displacement pumps and occasionally with variable
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pumps. The load may be a cylinder, a motor or any other

hydraulic device. This type of system is said to be load-
sensitive. That is, the pump delivers only the pressure
required to move the load. An open hydraulic circuit
contains at least one pump supplied with liquid from a
tank or a reservoir, usually at atmospheric pressure. The
discharge of the pump or pumps is directed through
appropriate valves to the hydraulic cylinder or motor
thereby providing the desired linear or rotary force and
motion.
Closed-Centre System
In this system, a pump can rest when the oil is not

required to operate a function. This means that a control
valve is closed in the center, stopping the flow of the oil
from the pump.

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The closed-centre system cuts off pump flow when the

valve is in the neutral position. In these conditions, the
pump flow is directed through the relief valve, which can
be particularly wasteful of input energy as well as
generating considerable fluid heating. Thus this particular
system would normally only be used with a pressure
compensated pump where the output is automatically
reduced to zero when pressure increases to a preset level.
The actual energy loss from the pump operating in these
conditions can then be quite low. A variable displacement
pump is generally used in this circuit.
• Graphic Symbols
Hydraulic Graphic Symbols are used in place of actual
component drawings because they are easier to read and
quick to draw. The symbols are of a standard recognized
worldwide.
Lines and Line Functions

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Pumps
Motors
Actuators
Valves

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• Hydraulic Pumps
Every hydraulic system uses one or more pumps to
pressurize the hydraulic fluid. The fluid under pressure, in
turn, performs work in the output section of the hydraulic
system. Thus, the pressurized fluid may be used to move
a piston in a cylinder or to turn the shaft of a hydraulic
motor.
Types of Pumps
Three types of pumps find use in hydraulic system:
1. Positive Displacement Pumps
2. Negative Displacement Pumps, and
Positive Displacement Pumps

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With these pumps, a definite volume of liquid is delivered for

each cycle of pump operation, regardless of resistance, as long
as the capacity of the power unit driving a pump is not
exceeded. If an outlet is completely closed, either the unit
driving a pump will stall or something will break. Therefore, a
positive-displacement-type pump requires a pressure regulator
or pressure-relief valve in the system. These pumps can be
classified as follows:
1. Fixed Displacement Pumps
2. Variable Displacement Pumps
Fixed Displacement Pumps
Gear Pumps
Gear Pump
Gear Pumps are further of two types:

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1. External Gear Pumps
2. Internal gear Pumps
External Gear Pump
The external gear pump is capable of developing higher fluid

pressures than a vane pump and can also be run at higher
speeds.
Figure shows the operating principle of an external

gear pump.
It consists of a driving gear and a driven gear enclosed in a

closely fitted housing. The gears rotate in opposite directions
and mesh at a point in the housing between the inlet and outlet
ports.
As the teeth of the two gears separate, a partial vacuum forms

and draws liquid through an inlet port into chamber A. Liquid in
chamber A is trapped between the teeth of the two gears and
the housing so that it is carried through two separate paths
around to chamber B. As the teeth again mesh, they produce a
force that drives a liquid through an outlet port.

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Internal Gear Pumps
Certain use is made of internal gear pumps for hydraulic

services. One internal gear is located within an outer gear ring,
the tooth form being chosen so that each tip of each internal
gear is always in contact with the inner surface of the outer
ring. Rotation produces a series of contracting and expanding
pockets transferring oil from the inlet side to the outlet side.
The teeth of one gear project outward, while the teeth of the
other gear project inward toward the center of the pump.
 The two gears mesh on one side of a pump chamber,

between an inlet and the discharge. On the opposite side
of the chamber, a crescent-shaped form stands in the
space between the two gears to provide a close tolerance.
 The rotation of the internal gear by a shaft causes the

external gear to rotate.
 Since the two are in mesh. Everything in the chamber

rotates except the crescent, causing a liquid to be trapped
in the gear spaces as they pass the crescent.
 Liquid is carried from an inlet to the discharge, where it is

forced out of a pump by the gears meshing. As liquid is

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carried away from an inlet side of a pump, the pressure is

diminished, and liquid is forced in from the supply source.
 The size of the crescent that separates the internal and

external gears determines the volume delivery of this
pump. A small crescent allows more volume of a liquid per
revolution than a larger crescent.
Variable Displacement Pumps
Vane Pumps
Vane Pumps are particularly suited to medium-pressure,

medium-speed duties and hence have the particular advantage
over gear pumps that the rotor can be hydraulically balanced,
thus minimizing bearing loads. Their main application is for low
and medium-pressure systems requiring a compact low cost
pump (eg machine tool hydraulic systems), their versatility
being an attractive feature.
Unbalanced Vane Pump
Unbalanced design, (as shown in figure), a cam ring's shape is

a true circle that is on a different centerline from a rotor's.

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• Pump displacement depends on how far a rotor and ring

are eccentric.
• The advantage of a true-circle ring is that control can be

applied to vary the eccentricity and thus vary the
displacement.
• A disadvantage is that an unbalanced pressure at the

outlet is effective against a small area of the rotor's edge,
imposing side loads on the shaft.
Balanced Vane Pump
In the balanced design (as shown in figure), a pump has a

stationary, elliptical cam ring and two sets of internal ports.
• A pumping chamber is formed between any two vanes

twice in each revolution.
• The two inlets and outlets are 180 degrees apart.
• Back pressures against the edges of a rotor cancel each

other.

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• Recent design improvements that allow high operating

speeds and pressures have made this pump the most
universal in the mobile-equipment field.
Piston Pumps
 Piston pumps offer high volumetric efficiencies together

with virtually no limit on capacity, and thus covering a
wide range of delivery requirements. Because of the
greater complexity of construction, however, they are
seldom competitive in smaller sizes with gear or vane
pumps, unless high system pressures are required. In this
respect they are superior to all other types of pump,
although the pressure rating of a piston pump is governed
by the types of the valve which can be employed with the
design. Piston pumps are either radial or axial.
Radial Piston Pumps
In a radial piston pump, the pistons are arranged like wheel

spokes in a short cylindrical block.
 A drive shaft, which is inside a circular housing, rotates a

cylinder block. The block turns on a stationary pintle that
contains the inlet and outlet ports.
 As a cylinder block turns, centrifugal force slings the

pistons, which follow a circular housing.

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 Housing’s centerline is offset from a cylinder block's

centerline. The amount of eccentricity between the two
determines a piston stroke and, therefore, a pump's
displacement.
• Controls can be applied to change housing's location and

thereby vary a pump's delivery from zero to maximum.
Axial Piston Pumps
 In hydraulic systems with a workingpressure above aprox.

250 bar the most used pumptype is the axial piston pump.
 The pistons move parallel to the axis of the drive shaft.

The swashplate is driven by the shaft and the angle of the
swashplate determines the stroke of the piston.
 The valves are necessary to direct the flow in the right

direction. This type of pump can be driven in both
directions but cannot be used as a hydromotor.

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 The animation shows how the displacement of an axial

piston pump can be adjusted. In this example we use an
axial piston pump with a rotating cylinder barrel and a
static' swashplate.
 The cylinder barrel is driven by the drive shaft which is

guided through a hole in the swashplate. The position
(angle) of the swashplate determines the stroke of the
pistons and therefore the amount of displacement
(cm3/omw) of the pump.
 By adjusting the position of the swashplate the amount of

displacement can be changed. The more the swashplate
turns to the vertical position, the more the amount of
displacement decreases.
In the vertical position the displacement is zero. In that

case the pump may be driven but will not deliver any oil.
Normally the swashplate is adjusted by a hydraulic
cylinder built inside the pumphousing.

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• Hydraulic Actuators
• A hydraulic actuator receives pressure energy and
converts it to mechanical force and motion.
• An actuator can be linear or rotary.
• A linear actuator gives force and motion outputs in a

straight line. It is more commonly called a cylinder but is
also referred to as a ram, reciprocating motor, or linear
motor.
• A rotary actuator produces torque and rotating motion. It

is more commonly called a hydraulic motor or motor
• Hydraulic Motors
• Hydraulic motors convert hydraulic energy into
mechanical energy.

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• In industrial hydraulic circuits, pumps and motors are

normally combined with a proper valving and piping to
form a hydraulic-powered transmission.
 A pump, which is mechanically linked to a prime mover,

draws fluid from a reservoir and forces it to a motor. A
motor, which is mechanically linked to the workload, is
actuated by this flow so that motion or torque, or both, are
conveyed to the work.
Figure shows the basic operations of a hydraulic motor.
 The main types of motors are gear, vane, and piston. They
can be unidirectional or reversible. (Most motors designed
for mobile equipment are reversible.)

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External Gear Motor Radial Piston/Cam Motor
Hydraulic Motor Applications:
Compact and extremely efficient, small hydraulic motors

can be used for various machining operations like boring,
reaming, drilling etc. Due to their small size they are tools
of choice for applications like:
 Electric motor coil winding
 Oil pipeline inspection equipment
 Undersea camera manipulation
 Jumbo jet maintenance jacks
 Milling and sawing applications
 Dynamite blast hole pump drive
 Automatic clamping
 Textile washing agitators
 Orange peeling machines
 Fan drives
 Diamond wheel dresser
 Drill and tap machine tool
 Chicken processing machinery
 Conveyor drives
• Cylinders
• A cylinder is a hydraulic actuator that is constructed of a
piston or plunger that operates in a cylindrical housing by
the action of liquid under pressure.

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• Cylinder housing is a tube in which a plunger (piston)

operates.
• Figure shows the basic parts of a cylinder.
• In a ram-type cylinder, a ram actuates a load directly. In a

piston cylinder, a piston rod is connected to a piston to
actuate a load.
• An end of a cylinder from which a rod or plunger protrudes

is a rod end. The opposite end is a head end. The
hydraulic connections are a head-end port and a rod-end
port (fluid supply).
Single-Acting Cylinder.
This cylinder (above Figure) only has a head-end port and

is operated hydraulically in one direction.
• When oil is pumped into a port, it pushes on a plunger,

thus extending it. To return or retract a cylinder, oil must
be released to a reservoir. A plunger returns either
because of the weight of a load or from some mechanical
force such as a spring.
• In mobile equipment, flow to and from a single-acting

cylinder is controlled by a reversing directional valve of a
single-acting type.

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Double-Acting Cylinder.
This cylinder must have ports at the head and rod ends.
 Pumping oil into the head end moves a piston to extend a

rod while any oil in the rod end is pushed out and returned
to a reservoir.
 To retract a rod, flow is reversed. Oil from a pump goes

into a rod end, and a head-end port is connected to allow
return flow.
 The flow direction to and from a double-acting cylinder

can be controlled by a double-acting directional valve or
by actuating a control of a reversible pump.
Double-Acting Cylinder
• Valves
• Valves are used in hydraulic systems to control the

operation of the actuators.
• Valves regulate pressure by creating special pressure

conditions and by controlling how much oil will flow in
portions of a circuit and where it will go.
 The three categories of hydraulic valves are pressure-

control, flow-control, and directional-control.
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 Some valves have multiple functions, placing them into

more than one category.
Valves are rated by their size, pressure capabilities, and

pressure drop/flow.
Pressure-Control Valves
Pressure level control will fall into families associated with the
function to be performed. We can divide these categories into
six basic families and several subfamilies.
1. Relief and/or Safety Valves, first, limit the maximum

system pressure which, in turn, protects the system
components, piping, and tubing; and second. Limit the
maximum output force of the hydraulic system.
Relief Valve
2. Sequence Valves are used to assure that one operation

has been completed before another function is performed.
They operate by isolating the secondary circuit from the
primary circuit until the set pressure is achieved.
3. Counter balance, over centre, holding, or brake valves are

a broad range of pressure valves which controls a load
induced pressure to hold and control the motion of the
load. This group of valves provides balancing forces which
prevent the load from running away because of its own
weight or because of inertia.

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Counterbalance Valve
4. Unloading Valves are usually used in circuits with two or

more pumps or in circuits incorporating accumulators. The
valve operates by sensing pressure in the system
downstream of a check valve. Once a certain pressure
level is obtained, the unloading valve unloads its pump to
tank.
Relief, Unloading and Check combination
5. Reducing Valves are used to limit a certain branch of the

hydraulic circuit to a pressure lower than the relief valve
setting for the rest of the system. By reducing pressure in
the secondary circuit, we can independently limit the
output force to that in the primary circuit.

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Reducing Valve
1 Control Spool 6 Poppet

2 Orifice 7 Relief Valve Poppet
3 Orifice 8 Spring
4 Orifice 9 Fluid Channel
5 Flow past poppet 1 Pilot Section
0
Flow Control Valves
Flow-control valves are used to control an actuator's

speed by metering flow. Metering is measuring or
regulating the flow rate to or from an actuator. The
simplest form of a restrictor or throttling valve is a unit
incorporating an orifice. If restriction is required in both
directions this need be nothing more than a simple orifice
plate incorporated in a suitable fitting.

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Flow Control Valve
For one-way restriction a spring-loaded poppet valve may

be used, with the orifice drilled through the valve or a
fixed orifice with a spring-loaded tapered needle. The
latter has the advantage of rendering the restriction
characteristics independent of the fluid viscosity.
Alternatively, the needle may be made adjustable, so that
the valve can be adjusted to provide different throttling
characteristics. There are many alternative designs,
including multi-orifice restrictors, screw and plunger, but
needle and orifice configurations are the more usual.
Directional Control Valves (DCV)
Directional-control valves also control flow direction.

However, they vary considerably in physical
characteristics and operation. Directional Control Valves
provide links between various parts of the hydraulic
system, by connecting of disconnecting and/or changing
the oil flow direction. There are various types of DCV; in
hydraulics the spool valve type is most common.

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Spool Valve type DCV for OLSS circuit
Spool Valve type DCV for CLSS circuit
• Hydraulic Excavators
Introduction
The hydraulic excavators are the earth movers playing a
major role in the development of the infrastructure like
excavation, road construction, building construction,
granite mining, ore mining, coal mining etc. The hydraulic
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excavators are the machines, which are powered by the

hydraulic power for the earth excavation. The fabricated
components of machinery are under carriage, revolving
frame, boom, arm, and bucket.
Earth Moving Machine

Definition: It is a self propelled or towed machine on
wheels, crawler of legs having equipment or attachment
(working tool) primarily designed to perform excavating,
loading, transporting, spreading, compacting or trenching
of earth, rock and similar material.
According to IS: 12138-1987 an excavator is a self-

propelled crawler or wheeled machine with an upper
structure capable of minimum 360 degrees rotation which
excavates, swings and discharges, material by the action
of the bucket fitted to the boom and arm or telescopic
boom without moving the chassis or undercarriage during
any part of the working cycle of the machine. Excavator is
a multipurpose earthmoving machine, which can perform
many duties in the field.

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Such as digging earth, mining, and loading quarrying

apart from other activities like well-digging, material
handling. The excavator is the only earthmoving machine
capable of working in all directions.
Operating Principle
Mechanical energy is transmitted from the engine (prime
mover- electric motor or diesel engine) to hydraulic
energy by the pumps. The flow of the oil generated by the
pump is passed through the control valves to the output
devices such as hydraulic cylinders (which cause relative
movements of boom, arm and bucket with respect to each
other and to the upper structure) and hydraulic motors
(for swing of the upper structure with respect to the
undercarriage and travel of the equipment on the ground
and for the other auxiliary functions).
Special hydraulic circuits are incorporated which give

optimum use of hydraulic energy and have safety feature
for components thereby reducing losses to minimum.
Excavator
Excavators are heavy equipment used in civil works and
surface mining. An excavator, also called a 360-degree
excavator or digger, sometimes abbreviated simply to a
360, is an engineering vehicle consisting of a backhoe and
cab mounted on a pivot (turntable is a more apt
description) atop an undercarriage with tracks or wheels.
The term excavator is sometimes used as a general term
for any piece of digging equipment.

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• Types of Hydraulic Excavators
1. Crawler Excavator
Applications:
1. Used in soft terrain- more mobility and stability
2. Heavy excavation-quarry and mining operation
3. Where there is no need for frequent or high speed

movement of the machine
4. Where terrain is uneven or sharp rock segment
2. Wheeled Excavator
Applications:
1. Rapid job-job mobility is important

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2. Wherever crawler traction is impractical like legal
 Regulations
 Work floor damage
 Demand for speed and mobility
• Nomenclature of hydraulic
excavator (crawler type)

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Base Machine, crawler excavator
1 Undercarriage chassis 6 Revolving frame

2 Swing bearing 7 Track assembly
3 Upper structure 8 Track Pad
4 Cabin 9 Sprocket
5 Counterweight 1 Idler
0
Loader- General Nomenclature
1 Boom pivot 5 Arm cylinder

2 Arm pivot 6 Bucket pivot
3 Arm 7 Bucket
4 Boom cylinder 8 Bucket cylinder

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Excavators often have attachments, or you can purchase

additional attachments to fit the machinery. A few of the
attachments include jackhammers (breakers), shovels,
grapples, augers, etc. Grapples are similar to claws and are
used to grasp objects (trees, stumps, etc.). Hydraulic Mining
Excavators often uses shovels. Finally, augers are similar to a
drill bit, and are used to move materials.
The role of excavators is to dig holes, trenches, and

foundations. Excavators use large machinery with hinge metal
buckets, which are often attached to hydraulic arms, while
using the equipment to move heavy or bulky quantities of soil
or earth.
• Classification of Hydraulic Excavator

is done based on
1. Bucket capacity: Volumetric capacity of bucket.
2. Operating weight: Total dead weight of machine in

“tons”.
3. Rated horsepower: of the engine in kW/HP
4. Ground pressure: force/unit area of contact machine

exerted on ground by the machine.
5. Swing speed: maximum attainable revolving speed of

the upper structure in rev/min.
6. Travel speed: in km/hr.

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7. Grade ability: maximum ability of machine to climb a

slope expressed in percentage.
8. Boom length: straight-line length between centres of

hinge points of the boom.
9. Arm length: straight-line length between centres of

hinge points of the arms.
10. Break out force: force exerted at the tip of the bucket
due to hydraulic thrust of the cylinder, which tends to
move the bucket against resistance.
11. Arm crowd force: force exerted at the tip of the

bucket due to hydraulic thrust of the cylinder, which
moves the arm.
12. Hydraulic pumps: can be fixed displacement or

variable flow pump. Amongst fixed displacement gear
or axial piston. Variable displacement is axial piston or
radial piston.
13. Operating pressure: maximum attainable rate of flow

generated by a hydraulic circuit, which is determined by
the setting of relief valve.
14. Flow rate: maximum attainable rate of flow

generated by a hydraulic pump, which is attained at the
minimum hydraulic pressure in the circuit.
15. Digging reach: maximum reach of the excavator

with a particular attachment that is expressed as the
distance from the centre of the machine to the tip of
maximum extended attachment in the horizontal plane.
16. Digging depth: maximum distance below the level

ground that the tip of the attachment can reach.
17. Dumping height: maximum height at which the

bucket can dump the prior filled material.

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18. Cutting height: maximum height up to, which the

attachment can cut or dig in the vertical plane.
19. Lifting capacity: maximum capacity of the machine

to carry material with bucket in the curled position and
both boom & arm fully extended.
• Applications of excavators
1. Below ground level Applications
 Canal excavation
 Trench digging
 Pipe laying
 Burrow pit excavation
 Land levelling
2. Below/above ground level Applications
 Well sinking
 Dredging
 Handling of loose material
3. Above ground level Applications (with shovel

attachment- bottom/forward dumping)
 Mining
 Quarrying

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 Bulk earthmoving against face
 Tunnelling
4. Above ground level Applications (with special

attachment)
 Rock breaking, Demolition
 Wood handling
 General construction- Vibratory pile drivers, excavators
 Scrap handling

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CLSS
Features
CLSS stands for Closed Centre Load Sensing System and is
featured as follows:
• Fine controllability without affect of load.
• Controllability that allows digging even in the fine control

mode.
• Ease of compound operation in which the flow distribution

performance depends on spool opening area during
compound operation.
• Saving of energy by variable pump control.
• Better fuel economy.
• Less system heat.
Configuration
• The CLSS consists of a variable displacement piston pump,

a control valve and actuators.
• The pump body consists of a main pump, a PC valve and

an LS valve.

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(courtesy L&T-Komatsu)
• Load Sensing System in CLSS circuit

Load Sensing System is a hydraulic system that senses and
provides only the pressure and flow required by the hydraulic
system. The components required to accomplish the
characteristics of the load sensing system are: A variable
volume piston pump, which has a compensator that will allow
the pump to standby at low pressure when the system is not
being actuated. It will sense the flow requirements of the
system when it is being actuated and provide a variable flow
rate as the flow demands of the hydraulic system are varied.
The pump must also sense and respond to the varying pressure
requirements of the hydraulic system. Most hydraulic systems
do not operate at constant pressure. The hydraulic pressure will
vary as the load on the hydraulic system changes. A control
valve, with special sensor passages and checks, is also required
to get the full benefit of the load sensing system. When the
hydraulic system is not being operated, and is in the standby
mode, the control valve must cut off the pressure signal from
the actuating cylinder (or motor) to the pump. This causes the

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pump to automatically go into low pressure standby when the

system is not being operated. When the control valve is
actuated, the control valve will pick up the pressure
requirement from the actuating cylinder (or motor) and send
that pressure signal back to the pump where the pump starts to
respond to the system pressure. The flow requirement of the
system is dictated by the movement of the spool. The system
flow requirement is sent back to the pump, through the signal
line, from the control valve. This combination of a load sensing
pump and load sensing control valve allows the total system to
provide only the flow and pressure required by the load sensing
system. This system automatically adjusts to the varying
pressure and flow demands. It remains in high pressure
standby until the load is overcome or the valve spool is
returned to neutral. It produces only enough flow to make up
for internal leakage.
Basic Principle of CLSS
1. Control of Pump Swash Plate Angle
• The pump swash plate angle (pump delivery) is controlled

so that the LS differential pressure ∆PLS, which is the
difference between the pump discharge pressure PP and
the LS pressure PLS (actuator load pressure) at the
control valve outlet, becomes constant.

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(LS differential pressure ∆PLS = Pump pressure PP – LS

pressure PLS)
• When the LS differential pressure ∆PLS reduces below the

set pressure of the LS valve (when the actuator load
pressure is high), the pump swash plate angle will move in

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the direction of maximum. When the set pressure is raised

(when the actuator load pressure is low), the pump swash
plate angle will move in the direction of minimum.

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2. Pressure Compensation Control
• A valve (pressure compensation valve) is mounted on the

outlet side of the control valve. In case of compound
operation of the actuator with this valve, the differential
pressure ∆P between the spool upstream
(inlet) and the downstream (outlet) of each valve becomes
constant irrespective of load (pressure). So, the flow from
the pump is distributed (compensated) in proportion to the
opening area S1 and S2 of each valve being operated.

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3. LS Valve

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• The LS valve detects loads and controls delivery.
• This valve controls main pump delivery Q with differential

pressure ∆PLS (PP – PLS) [that is called LS differential
pressure] between the main pump pressure PP and
control valve outlet pressure PLS.
• This valve is applied with main pump pressure PP,

pressure PLS that is obtained from constant valve output
[that is called LS Pressure] and pressure PSIG from the LS-
EPC valve [that is called LS Selection Pressure].
• The relations of differential pressure ∆PLS (= PP – PLS)

between main pump pressure PP and LS pressure PLS
with delivery Q vary with the LS selection current ISIG of
the LS-EPC valve as shown in figure.
• As ISIG changes from 0 to 1A, the spring set force changes

accordingly, and the selector point for pump discharge
amount changes from 0.64 to 2.1 MPa {6.5 to 21.5
kg/cm²} at the standard median.

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4. PC Valve
• When pump discharge pressure PP rises, the control valve

spool stroke will increase and the opening area will
enlarge. So, the PC valve controls pump delivery Q so that
delivery Q does not increase above a certain level
depending on discharge pressure PP.

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The valve also controls the pump absorbing hydraulic

horsepower to approximately equal horsepower so that
the pump absorbing horsepower does not exceed the
engine horsepower.
• This means that, when a load to the actuator increases

during operation and pump discharge pressure PP rises,
this valve will reduce pump delivery Q, or when pump
discharge pressure PP drops, this valve will increase
delivery Q.
• In this case, the relations between pump discharge

pressure PP and pump delivery Q change as shown in the
figure since the current value given to the PC-EPC valve
solenoid is regarded as a parameter.
• However, some PC valves have the function to sense

actual engine speeds in the heavy-duty operation mode
and to reduce pump delivery and recover speed when the
speed reduces due to increase of load.
• In other words, when an increase of load reduces engine

speed below the set value, the command current from the
controller to the PC-EPC valve solenoid will increase as
engine speed reduces and will reduce the pump swash
plate angle.

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44
5. Control Valve
The control valve is a CLOSED-SPOOL system. However

the hydraulic pump does go to minimum flow. UNLOAD
valves open to permit oil to return to tank when in neutral.

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45
This control valve consists of 6 spool valves and one

service valve.
Since one spool of this control valve is used for one work
equipment unit, the structure is simple.
 Spool Valve

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46
Hydraulic Spool Working of a

Spool Valve
A hydraulic spool valve is a switching device used to

control hydraulic devices. A spool valve can turn the flow
of hydraulic fluid from a hydraulic pump to an actuator on
and off by blocking off the route the fluid takes. It is a
cylinder inside a sealed case. It usually has valves leading
to the pump and the tank on one side, and valves leading
to one or more hydraulic devices on the other side.
Pressure can flow into the valve from the pump into the
hydraulic devices, or drain out of them back into a
hydraulic storage tank. A controller moves the valve back
and forth in its case to slide the spools into different
positions. The position of the rotor will only allow the
hydraulic fluid to flow in one direction to perform a specific
task.
In closed centre type when the engine or motor is started,

pump flow enters the directional control valve, but because it is
a closed centre type, the flow is blocked. A control valve is
equipped with special sensor passages and checks to get the
full benefit of the load sensing system. When the hydraulic
system is not being operated, and is in the standby mode, the
control valve must cut off the pressure signal from the
actuating cylinder (or motor) to the pump. This causes the
pump to automatically go into low pressure standby when the
system is not being operated. When the control valve is

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47
actuated, the control valve picks up the pressure requirement

from the actuating cylinder (or motor) and sends that pressure
signal back to the pump where the pump starts to respond to
the system pressure. The flow requirement of the system is
dictated by the movement of the spool. The system flow
requirement is sent back to the pump, through the signal line,
from the control valve.
Unload Valve
1. When the control valve is neutral
FUNCTION
• When the control valve is neutral, the delivery Q equivalent
to the pump minimum swash plate angle is released to the tank
circuit. At the time, pump discharge pressure PP is set to 2.45
MPa {25.0kg/cm2} with spring (3) inside the vale. (The LS
pressure PLS is 0 MPa {0kg/cm2}.)
(Courtesy L&T-Komatsu)
1. Unload Valve PLS: LS
circuit (pressure)
2. Sleeve PP:
Pump circuit (pressure)
3. Spring T: Tank
circuit
4. Spool

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48
OPERATION
• Pump discharge pressure PP is applied to the left end face of
spool (4) and LS pressure PLS is applied to the right end face.
• Since the LS pressure PLS is 0 when the control valve is
neutral, pump discharge pressure PP is only applied and is set
with the lead to spring (3).
• When pump discharge pressure PP rises to spring (3) load
(2.45 MPa {25.0 kg/cm2}), spool (4) will move toward the right
side and pump circuit PP will interconnect to tank circuit T
through the drill hole.
• Therefore, pump discharge pressure PP is set to 2.45 MPa
{25.0 kg/cm2}.
2. When the control valve is in the fine control mode

FUNCTION
• When the control valve is in the fine control mode and the
requested flow of the actuator is less than the pump minimum
swash plate angle, pump discharge pressure PP is set to LS
pressure PLS + 2.45 MPa {25.0 kg/cm2}.
When the differential pressure between discharge pressure PP
and LS pressure PLS comes to spring (3) load (2.45 MPa {25.0
kg/ cm2}), the unload valve will open and LS differential
pressure ∆PLS will come to 2.45 MPa {25.0 kg/cm2}.

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49
circuit (pressure)
2. Sleeve PP: Pump
circuit (pressure)
3. Spring T: Tank
circuit
4. Spool
OPERATION
• When the control valve is operated in the fine control mode,
LS pressure PLS will occur and will be applied to the right end
face of spool (4). At the time differential pressure between LS
pressure PLS and pump discharge pressure PP increases
because the opening area of the control valve spool is small.
• When the differential pressure between pump discharge
pressure PP and LS pressure PLS comes to spring (3) load
(2.45 MPa {25.0 kg/ cm2}), spool (4) will move to the right side
and pump circuit PP will interconnect to tank circuit T.
• This means that pump discharge pressure PP is set to the
spring force (2.45 MPa {25.0 kg/cm2} + LS pressure PLS, and

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50
LS differential pressure ∆PLS comes to 2.45 MPa {25.0

kg/cm2}.
3. When the control valve is operated

FUNCTION
• If the required flow of the actuator increases over the pump
minimum swash plate angle when the control valve is operated,
the flow to tank circuit T will be interrupted and pump delivery
Q will be completely flown to the actuator circuit.
circuit (pressure)
2. Sleeve PP:
Pump circuit (pressure)
3. Spring T: Tank
circuit
4. Spool
OPERATION
• When the control valve is operated with large stroke, LS
pressure PLS will occur and will be applied to the right end face
of spool (4). At the time, the opening areas of the control valve
spool are large and the difference between LS pressure PLS
and pump discharge pressure PP is small.
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51
• So, the differential pressure between pump discharge

pressure PP and LS pressure PLS does not reach spring (3)
load (2.45 MPa {25.0 kg/ cm2}) and spring (3) pushes spool (4)
to the left side.
• Then, pump circuit PP and tank circuit T are interrupted, and
pump delivery Q is completely flown to the actuator circuit.
Travel Valve
OPERATION
• When spool (1) is operated, the pump discharge pressure PP
will be led to actuator circuit A through bridge passage b from
flow control valve (2) and spool notch a.
• At the same time, the actuator circuit pressure PA moves
pressure reducing valve (3) to the right side, and notches c and
d interconnect to the travel junction circuit e and LS circuit PLS
respectively.

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• So, actuator circuit pressure PA (= A) is led from notch c to

LS circuit PLS through notch d.
 The travel circuit is different from the work equipment
circuit, actuator circuit pressure PA is directly led to the
LS circuit PLS.
5. Self Pressure Reducing Valve
P1: From pump 1. Control Valve

block
PR: Supply to solenoid valve, 2. Valve (sequence

valve)
PPC valve and EPC valve. 3. Spring
T: To hydraulic tank

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53
1. Screw 8.
Valve(pressure reducing valve)
2. Poppet 9. Spring
(safety valve)
3. Spring (pressure reducing valve pilot) 10. Ball
4. Spring (pressure reducing valve main) 11. Filter
 The self pressure reducing valves reduces the discharge

pressure of the main pump and supplies it to the
solenoid valve, the PPC valve, etc. as the control
pressure.

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7. PPC Valve
P: From main pump P3: Left: Swing

RIGHT/Right: Bucket Curl

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55
P1: Left: Arm OUT/Right: Boom LOWER P4: Left: Swing

LEFT/Right: Bucket Dump
P2: Left: Arm IN/Right: Boom RAISE T: To tank
1. Spool 6. Nut
(for linking the lever)
2. Metering spring 7. Joint
3. Centring spring 8. Plate
4. Piston 9.
Retainer
5. Disk 10.
Body

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56
Operation
1) At neutral
• Ports A and B of the control valve and ports P1 and P2 of the
PPC valve are connected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)

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57
2) During fine control (neutral→ fine control)

When piston (4) starts to be pushed by disc (5), retainer (9) is
pushed; spool (1) is also pushed by metering spring (2), and
moves down. When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same time, it is
connected to pump pressure chamber PP, so pilot pressure oil
from the main pump passes through fine control hole f and
goes from port P1 to port A. When the pressure at port P1
becomes higher, spool (1) is pushed back and fine control hole
f is shut off from pump pressure chamber PP. At almost the
same time, it is connected to drain chamber D to release the
pressure at port P1.
When this happens, spool (1) moves up or down so that force of
metering spring (2) is balanced with the pressure at port P1.
The relationship in the position of spool (1) and body (10) (fine
control hole f is at a point midway between drain hole D and
pump pressure chamber PP) does not change until retainer (9)
contacts spool (1). Therefore, metering spring (2) is
compressed proportionally to the amount of movement of the
control lever, so the pressure at port P1 also rises in proportion
to the travel of the control lever. In this way, the control valve
spool moves to a position where the pressure in chamber A
(the same as the pressure at port P1) and the force of the
control valve spool return spring are balanced. (Fig. 2)

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58
3) During fine control (when control lever is returned)

When disc (5) starts to be returned, spool (1) is pushed up by
the force of centring spring (3) and the pressure at port P1.
When this happens, fine control hole f is connected to drain
chamber D and the pressure oil at port P1 is released. If the
pressure at port P1 drops too far, spool (1) is pushed down by
metering spring (2), and fine control hole f is shut off from
drain chamber D. At almost the same time, it is connected to
pump pressure chamber PP, and the pump pressure is supplied
until the pressure at port P1 recovers to a pressure that
corresponds to the lever position. When the spool of the control
valve returns, oil in drain chamber D flows fine control hole f' in
the valve on the side that is not working. The oil passes

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59
through port P2 and enters chamber B to fill the chamber with

oil. (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (4), and retainer (9) pushes
down spool (1), fine control hole f is shut off from drain
chamber D, and is connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the main pump passes
through fine control hole f and flows to chamber A from port
P1, and pushes the control valve spool. The oil returning from
chamber B passes from port P2 through fine control hole f' and
flows to drain chamber D. (Fig. 4)

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8. Engine Control

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61
1. Starting switch
2. Fuel control dial
3. Governor motor
4. Starting motor
5. Linkage
6. Battery relay
7. Battery
8. Engine throttle and pump controller
9. Fuel injection pump
The engine can be started and stopped with only starting

switch. The engine throttle and pump controller receives the
signal of fuel control dial and transmits the drive signal to
governor motor to control the governor lever angle of fuel
injection pump and control the engine speed.
1. OPERATION OF SYSTEM
Starting engine
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62
• When the starting switch is turned to the START position, the

starting signal flows to the starting motor, and the starting
motor turns to start the engine. When this happens, the engine
throttle and pump controller checks the signal from the fuel
control dial and sets the engine speed to the speed set by the
fuel control dial.
Engine speed control
• The fuel control dial sends a signal to the engine throttle and
pump controller according to the position of the dial. The
engine throttle and pump controller calculates the angle of the
governor motor according to this signal, and sends a signal to
drive the governor motor so that it is at that angle. When this
happens, the operating angle of the governor motor is detected
by the potentiometer, and feedback is sent to the engine
throttle and pump controller, so that it can observe the
operation of the governor motor.
Stopping engine

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63
• When the starting switch is turned to the STOP position, the

engine throttle and pump controller drives the governor motor
so that the governor lever is set to the NO INJECTION position.
• When this happens, to maintain the electric power in the
system until the engine stops completely, the engine throttle
and pump controller itself drives the battery relay.
Fuel Control Dial
FUNCTION
• The fuel control dial is installed under the monitor panel, and
a potentiometer is installed under the knob. The potentiometer
shaft is turned by turning the knob.
• As the potentiometer shaft is turned, the resistance of the
variable resistor in the potentiometer changes and a throttle
signal is sent to the engine throttle and pump controller. The
hatched area in the graph shown at right is the abnormality
detection area.

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64
Governor Motor
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
OPERATION
While motor is stopped
• Electric power is applied to both phases A and B of the motor.
While motor is running

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65
• The engine throttle and pump controller supplies a pulse

current to phase A and B, and the motor revolves,
synchronizing to the pulse.
FUNCTION
• The motor is turned according to the drive signal from the
engine throttle and pump controller to control the governor
lever of the fuel injection pump.
This motor used as the motive power source is a stepping
motor.
• A potentiometer for feedback is installed to monitor the
operation of the motor.
• Revolution of the motor is transmitted.
9. Electric Control System

CONTROL FUNCTION

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66
Engine and Pump Control Function
FUNCTION
• This function is for selecting any of the four working modes
"A," "B", "E" and "L" with the working mode selector switch on
the monitor panel. The controller can select optimum engine
torques or pump absorption torques for works to be expected.

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67
• The controller detects the engine governor speed set with the
fuel control dial depending on the pump absorption torque set
in each mode and detects actual engine speeds. Then, the
controller controls all torques at each output point of the
engine so that the pump can absorb them.
• When an engine speed was lowered, the controller prevents
the engine from stopping by throttling the pump absorption
toque.
1. CONTROL METHOD IN EACH MODE

Mode A
• Matching point in Mode A
A Travel (A1) 66.2 KW/2,200 rpm

{88.7 HP/2,200 rpm}
A Work (A2) 65.5 KW/2,200 rpm
{87.8 HP/2,200 rpm}

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68
• When a load to the pump increases and the pressure rises

and the engine speed lowers. At the time, the controller
reduces the pump delivery so that the
speed lowers to the speed at the full output point or so. If the
pressure drops on the contrary, the controller increases the
pump delivery so that the speed comes to the speed at the full
output point or so. The controller repeats these controls so that
the engine can always be used at speeds at the full output
point or so.
Mode E/ Mode B/ Mode L
Mode E B L
Partial Output
Point 90% 90% 55%
Model PC-130-7
Mode E 58.8 kW/2,000 rpm
{78.9 HP/2,000 rpm}
Mode B 58.8 kW/2,000 rpm
{78.9 HP/2,000 rpm}
Mode L 36.8 kW/1,500 rpm
{70 HP/1,500 rpm}

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69
• At this time, the controller keeps the pump absorption torque

along the constant horsepower curve and lowers the engine
speed by the composite control of the engine and pump.
• By this method, the engine is used in the low fuel
consumption area.
2. FUNCTION TO CONTROL PUMP DURING TRAVEL

• If the machine travels in mode work A, B, E, or L, the working
mode does not change, but the pump absorption torque and
engine speed rise to travel A mode.

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70
2. PUMP/VALVE CONTROL FUNCTION

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71
FUNCTION
• The machine is matched to various types of work properly
with the 2-stage relief function to increase the digging force,
etc.
1) Cut-off function
• When the cut-off function is turned on, the PC-EPC current is
increased to near the maximum value. By this operation, the
flow rate in the relief state is lowered to reduce fuel
consumption.
• Operating condition for turning on cut-off function.
Condition- The average value of the front and rear pressure
sensors is above 27.9 MPa {285 kg/cm2} and the one-touch
power maximizing function is not turned on.
The cut-off function does not work, however, while the machine
is travelling in mode A, the lock switch is turned on.
2) 2-stage relief function

• The relief pressure in the normal work is 31.9 MPa {325
kg/cm2}. If the 2 stage relief function is turned on, however,
the relief pressure rises to about 34.8 MPa {355 kg/cm2}. By
this operation, the hydraulic force is increased further.
• Operating condition for turning on 2-stage relief function
Condition Relief Pressure
• During travel 31.9 MPa
• When swing lock switch is {325 kg/cm2}
turned on ↓
• When one-touch power 34.8 MPa
maximizing {355 kg/cm2}
function is turned on
• When L mode is operated

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72
3. ONE-TOUCH POWER MAXIMIZING FUNCTION
FUNCTION
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73
• Power can be increased for about 8.5 sec. By operating the

left knob switch.
1) One-touch power maximizing function
• When the operator needs more digging force to dig up a large
rock, etc., if the left knob switch is pressed, the hydraulic force
is increased about 9% to increase the digging force.
• If the left knob switch is turned on in working mode "A" or
"E", each function is set automatically as shown below.
Working Mode Engine/Pump 2-stage relief Operation

Control function Time
A, E Matching at 31.9 MPa Automatically
rated {325 kg/cm2} reset at 8.5
output point ↓ sec
34.8 MPa
{355 kg/cm2}
4. AUTO-DECELERATION FUNCTION
FUNCTION

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74
• If the all control levers are set in NEUTRAL while waiting for a
dump truck or work, the engine speed is lowered to the
medium level automatically to reduce the fuel consumption and
noise.
• If any lever is operated, the engine speed rises to the set
level instantly.
OPERATION
When control levers are set in neutral
• If all the control levers are set in NEUTRAL while the engine
speed is above the decelerator operation level (about 1,400
rpm), the engine speed lowers instantly to the first deceleration
level about 100 rpm lower than the set speed.
• If 4 more seconds pass, the engine speed lowers to the
second deceleration level (about 1,400 rpm) and keeps at that
level until any lever is operated again.
When any control lever is operated
• If any control lever is operated while the engine speed is kept
at the second deceleration level, the engine speed rises
instantly.

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1

The industrial hydraulics system is a power transmission

Hydrodynamic systems depend upon the inertia of the

Liquid contained within an enclosed conductor is moved

Department of Mechanical Engineering

• Major Hydraulic Components

• Types of Hydraulic Circuits

In this system, a control-valve spool must be open in the

This type of system is commonly used with fixed

pumps. The load may be a cylinder, a motor or any other

In this system, a pump can rest when the oil is not

Department of Mechanical Engineering

The closed-centre system cuts off pump flow when the

Lines and Line Functions

Department of Mechanical Engineering

Department of Mechanical Engineering

1. Positive Displacement Pumps

2. Negative Displacement Pumps, and

Positive Displacement Pumps

Department of Mechanical Engineering

With these pumps, a definite volume of liquid is delivered for

1. Fixed Displacement Pumps

2. Variable Displacement Pumps

Fixed Displacement Pumps

Gear Pumps are further of two types:

1. External Gear Pumps

2. Internal gear Pumps

External Gear Pump

The external gear pump is capable of developing higher fluid

Figure shows the operating principle of an external

It consists of a driving gear and a driven gear enclosed in a

As the teeth of the two gears separate, a partial vacuum forms

Department of Mechanical Engineering

Internal Gear Pumps

Certain use is made of internal gear pumps for hydraulic

 The two gears mesh on one side of a pump chamber,

 The rotation of the internal gear by a shaft causes the

 Since the two are in mesh. Everything in the chamber

 Liquid is carried from an inlet to the discharge, where it is

Department of Mechanical Engineering

carried away from an inlet side of a pump, the pressure is

 The size of the crescent that separates the internal and

Variable Displacement Pumps

Vane Pumps are particularly suited to medium-pressure,

Unbalanced Vane Pump

Unbalanced design, (as shown in figure), a cam ring's shape is

Department of Mechanical Engineering

• Pump displacement depends on how far a rotor and ring

• The advantage of a true-circle ring is that control can be

• A disadvantage is that an unbalanced pressure at the

Balanced Vane Pump

In the balanced design (as shown in figure), a pump has a

• A pumping chamber is formed between any two vanes

• The two inlets and outlets are 180 degrees apart.

• Back pressures against the edges of a rotor cancel each

Department of Mechanical Engineering

• Recent design improvements that allow high operating

 Piston pumps offer high volumetric efficiencies together

Radial Piston Pumps

In a radial piston pump, the pistons are arranged like wheel

 A drive shaft, which is inside a circular housing, rotates a

 As a cylinder block turns, centrifugal force slings the

Department of Mechanical Engineering